1. ABERTURA ACIONADA POR PAINPOINT

Você está enfrentando custos operacionais crescentes e disponibilidade imprevisível em seu circuito primário de britagem?? Key challenges with primary gyratory crushers often include:
Tempo de inatividade não programado: Frequent mechanical failures or liner changes that halt upstream mining and downstream processing, custando milhares por hora em perda de produção.
Altos custos de manutenção: Excessive consumption of wear parts, complex lubrication system issues, and laborintensive servicing that strain maintenance budgets.
Taxa de transferência inconsistente: Inability to maintain optimal cavity levels and power draw, leading to bottlenecks and failing to meet designed plant capacity.
Rising Energy Expenditure: Mais velho, inefficient crusher designs consume disproportionate power per ton of processed material, impactando diretamente seus resultados financeiros.

Is your current primary crusher a reliable asset or a constant source of risk? The solution lies in selecting a modern OEM gyratory crusher engineered for total cost of ownership.

2. VISÃO GERAL DO PRODUTO

The OEM Gyratory Crusher is a heavyduty, primary compression crusher designed for the first stage of reducing runofmine ore to a manageable size for conveying and further processing. Its core operational workflow involves:
1. Ingestão de ração: Large feed material is directed into the crushing chamber from the top.
2. Esmagamento Compressivo: A mantle gyrates within a concave bowl, applying compressive force to reduce material by squeezing it against the stationary concaves.
3. Progressive Discharge: Crushed material gravitates downward through the narrowing chamber until it reaches the desired size and exits at the bottom.

This equipment is specifically scoped for hightonnage, mineração de rocha dura (cobre, minério de ferro, ouro) and largescale aggregate quarrying applications. It is not suited for abrasive recycling materials without specific alloy options or for operations requiring highly portable equipment.

3. RECURSOS PRINCIPAIS

Design de aranha patenteado | Base Técnica: Onepiece cast alloy steel construction with top shell integration | Benefício Operacional: Eliminates bolton spider arms, reducing stress points and potential for cracking under extreme load | Impacto do ROI: Até 40% longer service life on upper assembly components, reducing major rebuild frequency.

Intelligent Lube System (ILS) | Base Técnica: Automatizado, dualcircuit lubrication with realtime pressure/temperature monitoring and filtration | Benefício Operacional: Ensures optimal bearing protection under all loads; alerts operators to potential issues before failure | Impacto do ROI: Proven to extend bearing life by over 30% and prevent catastrophic luberelated downtime events.

STLF (StraightTaperLowerFlat) Concave Profile | Base Técnica: Optimized chamber geometry derived from crushability testing data | Benefício Operacional: Maintains consistent feed opening characteristics throughout liner life for stable throughput and product gradation | Impacto do ROI: Entrega até 15% more crushed tonnage per concave liner set compared to traditional profiles.

Estrutura Tubular & Mainshaft Design | Base Técnica: Forged highstrength steel mainshaft supported within a rigid, onepiece tubular frame | Benefício Operacional: Provides exceptional alignment stability and resists fatigue under cyclical loading for consistent operation | Impacto do ROI: Minimizes deflectionrelated wear on bushings and liners, reduzindo os custos de manutenção a longo prazo.

Integrated Control System (ICS) Interface | Base Técnica: Standardized PLC platform with MODBUS/J1939 protocols for plantwide integration | Benefício Operacional: Your operators gain realtime control over CSS (Configuração lateral fechada), consumo de energia, and lubrication from the central control room | Impacto do ROI: Enables precise process optimization for energy savings and target product size.

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Referência padrão da indústria | OEM Gyratory Crusher Solution | Vantagem (% Melhoria) |
| : | : | : | : |
| Disponibilidade (Agendado) | 92 94% | 96%+ (with ILS & Patented Spider) | +24% |
| Toneladas por MWh (Eficiência Energética) Linha de base = 100%| 100% Reference| 115 118%| +1518% |
| Tempo de troca do revestimento (Conjunto principal) Average = ~48 hrs| ~48 horas| ~36 hours| 25% |
| Consumo de peças de desgaste (g/ton crushed) Material Dependent Baseline = 100%| 100% Reference| ~8590%| 10 para 15% |

5. ESPECIFICAÇÕES TÉCNICAS

Faixa de capacidade: dependente do modelo, de 2,000 tph para mais 10,000 tph.
Potência do motor: Normalmente entre 450 kW e 1,200 kW (600 HP 1,600 HP), adaptado ao dever.
Abertura de alimentação: Tamanhos de abertura de 1,000 mm para 1,500 milímetros (39" para 59").
Principais especificações de materiais:
Quadro Principal & Concha superior: Aço fundido de alta resistência.
Manto & Côncavo: Ligas de aço manganês; optional premium alloys for specific abrasion/corrosion applications available.
Mainshaft: Forged highstrength alloy steel.
Dimensões Físicas: Pegada significativa; exact L x W x H varies by model. Requires engineered reinforced concrete foundation.
Faixa operacional ambiental: Projetado para temperaturas ambientes de 40°C a +50°C (40°F a +122°F). Dust seals rated for harsh environments.

6. CENÁRIOS DE APLICAÇÃO

Expansão da mina de cobre em grande escala

Desafio: An existing mine’s expansion required a new primary crushing station capable of handling an additional 12 million tpy of sulfide ore while operating at >95% availability in a remote location with high service costs.
Solução: Installation of a single largecapacity OEM Gyratory Crusher with the Intelligent Lube System (ILS) and remote monitoring capabilities.
Resultados: Rendimento de projeto alcançado dentro de três meses após o comissionamento. The ILS prevented two potential bearing failures in the first two years as flagged by its monitoring system. Disponibilidade média 96.7% over three years.

HighAbrasion Granite Quarry

Challenge A major aggregate producer faced unsustainable wear part costs and excessive downtime due to biweekly concave changes in their primary crushing stage.
Solution Replacement with an OEM Gyratory Crusher featuring the STLF concave profile and optional ultrawearresistant alloy liners specified for granite.
Results Liner service life increased from an average of 14 dias para 21 dias. This reduced annual scheduled liner change downtime by approximately 120 horas, while also lowering liner cost per ton by an estimated 18%.

7. CONSIDERAÇÕES COMERCIAIS

OEM Gyratory Crushers are capital investments priced according to size, capacity specifications (<tph), selected metallurgy options (<alloy grade), nível de automação (<control package). Pricing typically falls into distinct tiers based on inlet size (<42”, <54”, <60”+).

Optional features that affect final pricing include:
Regulamento de configuração automatizada () sistema
Premium alloy packages for mantles/concaves
Sensores avançados de monitoramento de condição (, temperatura)
Extended factory warranty packages

Comprehensive service agreements are available covering planned maintenance inspections parts supply (, rolamentos), technical support These agreements can be structured as fixedcost annual contracts providing budget certainty Financing options including leasing capital equipment loans are offered through certified partners

8. Perguntas frequentes

Q What are the lead times typically involved?
A Lead times vary based on model complexity current manufacturing capacity but generally range from

Q Can this crusher integrate with our existing PLC control system?
A Yes The Integrated Control System uses industrystandard communication protocols like MODBUS TCP/IP ensuring compatibility with most modern plant DCS systems

Q How does this design improve safety during maintenance?
A Key safety features include hydraulic setting adjustment eliminating manual work under tension integrated lifting points designed rigging procedures provided

Q What is included in standard commissioning?
A Standard commissioning includes field assembly supervision initial startup performance testing operator training Documentation includes detailed installation maintenance manuals

P São fornecidas garantias de desempenho?
A Yes performance guarantees covering throughput power consumption product gradation are contractually defined based on agreed feed material characteristics